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E-Z-GO ST 480 Offroad Vehicle User Manual

1. 3 30 CHANGING THE mecs 3 30 Fig 27 Oil Viscosity Chatt 3 31 CHANGING THE OIL tot FR 3 32 Fig 28 Drain sceau 3 32 LUBRICATION 3 32 Fig 29 Lubrication Points iioc iiie P HIVE DR ER 3 32 AIR CLEANER INSPECTION AND REPLACEMENT 3 33 Pre Cleaner Service Ie 3 33 Cartridge Service nes didi habs cat 3 33 FIG 20 AIFCIOSHOP en enue dana Ra 3 33 icm rdv E ae 3 34 Checking the Lubricant Level 3 34 Fig 31 Add Check and Drain Rear Axle Lubricant 3 34 STARTER GENERATOR BELT 3 34 Fig 32 Check Belt Tension with Gauge 3 35 Fig 33 Check Belt Tension with Finger 3 35 AGIUSHDO Tte Belt coude Pee 3 35 Fig 34 Adjust Belt Tension uito ep A DEA 3 35 BATTERYAGBEANIING s noA E used uda 3 36 Fig 35 Preparing Acid Neutralizing Solution 3 36 AIR INTAKE AND COOLING 5 2 3 36 Fig 36 Cleaning Air Intake and Cooling Fins 3 37 1 2 TITLE PAGE SPARK PLUGS Gees testas utei Mb e 3
2. 4 1 GENERAL SPECIFICATIONS 110 5 in 281 cm 38 in 96 Front 38 5 in 97 cm oes 42 5 in 108 Fig 1 Vehicle Dimensions GENERAL SPECIFICATIONS R ow d Maximum Recommended Ramp Maximum Recommended Side Tilt 9 147 25 14 Fig 2 Vehicle Incline Specifications 4 3 GENERAL SPECIFICATIONS LIMITED WARRANTY EMISSION CONTROL SYSTEM WARRANTY ENGINE OWNER WARRANTY POLICY STATEMENT 2 Refer to the Briggs amp Stratton Operating amp Maintenance Instructions provided Owner s Defect Warranty Rights and Obligations with vehicle for Engine Warranty information Refer to the Briggs amp Stratton Operating amp Maintenance Instructions provided with vehicle for Emission Control System Warranty information 5 1 LIMITED WARRANTY Notes 5 2 DECLARATION CONFORMITY NOT AVAILABLE AT PUBLICATION 6 1 DECLARATION OF CONFORMITY Notes 6 2 See Following Pages For Explanation Of These Pictograms 2 3 4 6 9 36 37 38 39 40 29 See Following Pages For Explanation Of These Pictograms 1
3. 10 SAFETY INFORMATION 2 1 OADBED 3 11 ELECTRIC LIFT BED OPERATIQON 2 3 11 OPERATION AND SERVICE INFORMATION 3 1 Fig 12 Electric Lift Switch 4 2220 3 11 BEFORE INI IAL USE E CCo aa PR nae 3 1 OPERATING THE VEHICLE 3 12 Fig 1 Initial Service Chatt oo c doc M Mta s ba 3 2 RUNAN 3 13 Fig 13 Check Oil Level Dipstick 3 13 eec 3 2 CODD STAR TING sobietar e A e 3 13 dr 3 2 STARTING AND 3 14 MODIFICATIONS TO VEHICLE 22 2 222 1 3 3 STARTING THE VEHICLE HILE esses ecco seposita 3 14 COMMONISENSEGBEBATION Sm rr ccs ae sore a EE UNE AM MDC d POWER CONSUMPTION 3 3 Eig 14 3 15 ENVIRONMENTAL CONCERNS 3 4 PET e OPTIONAL WINCH i 3 4 SUN AND WINDSHIELD 3 46 xL MEC E os i2 VOLT POWER OUTLET 3 16 AV ONUS 2 Fig 15 12 Volt Power Outlet scusate 3 16 ed ANE RONG COD 222 TOWI
4. Fig 35 Preparing Acid Neutralizing Solution Allow the solution to sit for at least three minutes use a soft bristle brush or cloth to wipe the tops of the battery to remove any residue that could contribute to the self discharge of the battery Rinse the entire area with low pressure clear water Do not use a pressure washer AIR INTAKE AND COOLING FINS To prevent possible burns engine parts should be kept clean to reduce risk of overheating and ignition of accumulated debris OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings After every off road use allow to cool and then check for a build up of dirt and debris in the air intake and cooling fins Dirt and debris may clog the engine s air cooling system Clean areas shown to prevent engine damage Ref Fig 36 on page 3 37 Keep linkages springs and controls clean Keep area around muffler free of any combustible mate rial Intake Fig 36 Cleaning Air Intake and Cooling Fins SPARK PLUGS Tool List Qty Required Spark plug socket 5 8 1 2 1 Ratchet 1 2 2 1 Plug gauge wire 1 1 Anti seize AR Torque wrench 1 2 drive ft 2 2202 1 Use
5. Light Bulb Replacement 3 21 LOW OIL PRESSURE INDICATOR LIGHT 3 9 FUSE REPLACEMENT AT tA 3 21 NC CELERATOR tota 3 9 VEHICLE WITH A DISCHARGED BATTERY 2 3 22 Fig 11 Accelerator Brake and Horn 3 10 TRANSPORTING VEHICLE canne ciiin cibi i eie 3 22 5 TITLE PAGE TOWING qM 3 22 NEUTRAL LOCK 3 22 Fig 20 Neutral EDO narah 3 23 HAULING aeea ial aaa hl E ET 3 22 SERVICE AND MAINTENANCE 3 23 SERIAL NUMBER PLATE LOCATION 3 25 Fig 21 Serial Number Plate Location 3 25 PERIODIC SERVICE SCHEDULE 3 26 Fig 22 Periodic Service Schedule 3 26 TIE MNSPEGCTHON ues 3 28 SEAT ROP MTS 3 28 0 23 Seat POD 3 29 REPLACING THE FUEL FILTER 3 29 CHECKING THE OIL LEVEL 3 29 Fig 24 Oil Fill Cap Dipstick and Fuel Filter 3 30 Fig 25 Clean Entire DIDSUCK 3 30 Fig 26 Check Oil Level on
6. Pressure Indicator Light Fig 9 Key Light Switch Low Oil Pressure Light and Fuel Gauge component damage the vehicle must be completely stopped before moving the direction selector Located on the console between the seats this lever permits the selec tion of either forward or reverse Ref Fig 10 on page 3 9 The vehicle should be left in forward when unattended CHOKE The choke is used to aid cold starting Ref Fig 10 on page 3 9 See Cold Starting Refer to page 3 14 for instructions on using the choke properly FUEL GAUGE An electric fuel gauge is located to the right side of the key light switch It indicates the amount of fuel in the tank Ref Fig 9 on page 3 9 LOW OIL PRESSURE INDICATOR LIGHT A low oil pressure indicator light is located on the dash panel Ref Fig 9 on page 3 9 If oil pressure drops below 1 4 psi 1 2 kg cm the oil pressure switch will activate the light Check oil level Refer to page 3 Parking Direction Selector Differential Locked Differential Lock Lever Stop Vehicle Before Moving Fig 10 Console Controls 29 If oil level is between ADD and FULL mark on dipstick a mechani cal problem exists within the engine and the vehicle must not be driven Contact a local Distributor or authorized Branch prevent engine damage do not operate engine until oil pressure is corrected Do not overfill engine Too much oil may cause smoking or al
7. Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings CAPACITIES AND REPLACEMENT PARTS Fuel Tank Fuel Oil Filter Air Cleaner Filter Pre Cleaner Filter P N 272490 Spark Plugs CHAMPION RC12YC P N 491055 030 76 mm Gap Starter Generator Belt P N 75690 01 Clutch Belt P N 75691 G01 Rear Axle Oil 40 oz 1 2 liters Fuse 15 amp P N 35212 G01 7 5 amp P N 35212 G05 Headlight Bulb Turn Signal Bulb 1157 P N 21759 G1 Tail Light Bulb 11157 P N 21759 G1 Fig 38 Capacities and Replacement Parts 3 40 FRONT SUSPENSION REAR SUSPENSION STEERING WHEEL SEATING CAPACITY TOTAL LOAD CAPACITY ST 480 STANDARD EQUIPMENT One 12 Volt Maintenance Free 515 CCA 82 Minute Reserve 16 11 9 kW 29 2 480 Twin Cylinder Overhead Valve Pressurized Lubrication with Spin Off Filter Magnetron Ignition with Transistor Module Replaceable Dry Cartridge Air Filter with Pre Filter amp Remote Intake Fixed Jet Bowl Carburetor Pulse Fuel Pump 13 32 1 Helical geared with Differential Lock and Ground Speed Governor Automatic Continuously Variable Transmission CVT 6 Gallon 23 Liters Tank 36 Ibs 16 kg Fuel Weight Dual Rear Wheel Self Adjusting Hydraulic Drum Brakes Hand Operated Mechanical Parking Brake Leaf Springs with Hydraulic Shock Absorbers Leaf Springs with Hydraulic Shock Absorbers Single Reduct
8. SELECTOR Check for wear and smooth movement lubricate shaft with light oil if required Y Check for excessive play and tightness of retaining nuts Lubricate use wheel bearing grease STEERING ASSEMBLY Lubricate unit and idler arm use wheel bearing grease Fig 22 Periodic Service Schedule ENGINE FUEL SYSTEM HARDWARE AND FASTENERS ENGINE KING PINS 3 27 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings RACK END BALL JOINT Lubricate use wheel bearing grease REAR AXLE Check for unusual noise and loose or missing mounting hardware DRIVE BELT Check for cracks fraying and excessive wear 250 300 HOURS or YEARLY includes items listed in previous tables amp the following FRONT WHEEL BEARINGS V Check and adjust as required see Technician s Repair and Service Manual REAR AXLE SERVICE BRAKES Check lubricant add lubricant SAE 30 oil as required Refer to page 3 34 Clean see Technician s Repair and Service Manual Check brake shoe linings see Technician s Repair and Service Manual FUEL FILTER Replace Refer to page 3 29 SPARK PLUGS Replace gap new plugs Ref Capacities and Replacement Parts on page 3 40 Refer to page 3 37 MUFFLER EXHAUST V Check mounting hardware check for leaks at head and muffler gaskets VALVES 500 HOURS V Check valve clearance refer to Brigg
9. TIE RODS LINKAGES Check for excessive play bent components or loose connections REAR AXLE Y Check for leakage add SAE 30 oil as required Refer to page 3 34 50 HOURS includes items listed in previous tables amp the following Change oil DO NOT OVERFILL Refer to page 3 30 see Note 1 and Note 2 on Pg 3 40 Check spark plug wires for cracks loose connections EXHAUST V Inspect clean spark arrester FRONT AXLE Check for damage to axle and loose or missing hardware FRONT SHOCK ABSORBERS Y Check for oil leakage and loose fasteners FRONT SPRINGS Check for loose hardware cracks at attachments FRONT WHEEL ALIGNMENT V Check for unusual tire wear align if required Y Check for binding cables PARKING PARK BRAKE Check for damage or wear Lubricate as required use light oil DO LUBRICATE CABLES ENGINE ELECTRICAL SYSTEM Check coil spark plug wires for cracks loose connections Y Check for leaks at tank cap system lines filters pump carburetor Check system lines for cracks deterioration THROTTLE GOVERNOR LINKAGE Check operation and governed speed V Check for loose or missing hardware and components Tighten or replace missing hardware 100 HOURS includes items listed previous tables amp the following BATTERY Clean battery amp terminals A Change oil filter Refer to page 3 32 see Note 1 on Pg 3 40 Change air cleaner cartridge if damaged or dirty Refer to page 3 33 see Note 3 on Pg 3 40 DIRECTION
10. care not to over tighten the plug Over tightening can cause damage to the aluminum cylinder head threads Remove and inspect the spark plugs at intervals per the Periodic Ser vice Schedule Ref Fig 22 on page 3 26 All new spark plugs should be properly gapped before installation Ref Fig 38 on page 3 40 Apply a light coat of anti seize compound and tighten to 15 ft lbs 20 Nm torque Fouled spark plugs are indicated by a wet black appearance This could be caused by a dirty air filter element or other restrictions in the air intake system Incorrectly adjusted valves spark plug wires which are in poor condition or poor quality fuel could also contribute to the prob lem Do not sand blast spark plugs They should be NOTE cleaned by scraping or wire brushing by hand and washing in a commercial solvent BRAKES The master cylinder is located under the driver side seat It is important to maintain proper fluid levels in the brake master cylin der The fill cap for the cylinder is located under the seat When check ing the fluid wipe off any dirt from the fill cap before removing it to prevent contamination Fluid level should be maintained at 1 4 6 mm below the top of the housing Use DOT 3 automotive brake fluid Daily Brake Test To prevent severe injury or death resulting from operating a vehicle with improperly operating brake sys tem the braking system must be properly maintained driving brake tests
11. is just below the bottom of the threaded hole If lubricant is to be added remove the fill plug and add lubricant SAE 30 oil using a funnel Add lubricant slowly until lubricant starts to seep 3 34 from the check plug hole Install the check plug and the fill plug In the event that the lubricant is to be replaced a drain plug is provided at the bottom of the differential housing Capacity of axle is 48 oz 1 4 liters E e Drain Plug Fig 31 Add Check and Drain Rear Axle Lubricant STARTER GENERATOR BELT TENSION Tool List Qty Required Belt tension 1 Me emo TE 1 LAUR e REEL 2 Socket 1 4 hex bit 3 8 1 Ratchet 3 8 1 G ckel 9 4 3 8 UNIVE 1 DOCKEE 1 2 3 8 ANAE RENE 1 I TT 1 Torque wrench 3 8 drive ft 169 1 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings The starter generator belt tension should be checked after the first 15 20 hours of operation and set to 75 80 lbs 34 36 kg A loose belt can cause audible vibration and NOTE squeal Tighten a new starter generator belt to 90 110 Ibs 41 50 kg tension when a gauge is applied half way between the two pu
12. light duty utility vehicle It is not an ATV All Terrain Vehicle The vehicle is not a toy and engaging in horseplay is dan gerous The vehicle should not be operated on public highways It OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings is not designed to comply with any DOT requirements The vehicle should be operated by persons with a valid driver s license Children should not operate this vehicle Refer to GENERAL SPECIFICATIONS for seating capacity Use the park brake when the vehicle is parked To prevent inadvertent movement when the vehicle is to be left unattended engage the park brake move direction selector to forward position turn key to OFF position and remove key Make sure that the direction selector is in correct position before attempting to start the vehicle Always bring the vehicle to a complete stop before shifting the direction selector and or differential lock Do not take vehicle out of gear while in motion coast Check the area behind the vehicle before operating in l everse occupants must be seated Keep entire body inside vehicle and hold on while vehicle is in motion The vehicle is not equipped with seat belts and is not designed with roll over protection The top and windshield do not provide protection from falling or flying objects A motorcycle helmet and protec
13. lt lt 4 55 Textron Company MANUAL INFORMATION For any questions on material contained in this manual contact a representative for clarification Head and understand all labels located on the vehicle Always replace any dam aged or missing labels On steep hills it is possible for vehicles to coast at greater than normal speeds encountered on a flat surface To prevent loss of vehicle control and possible serious injury speeds should be limited to no more than the maximum speed on level ground See vehicle specification Limit speed by applying the service brake Catastrophic damage to the drive train components due to excessive speed may result from driving the vehicle above specified speed Damage caused by excessive speed may cause a loss of vehicle control is costly is considered abuse and will not be covered under warranty Be sure that this manual remains as part of the permanent service record should the vehicle be re sold Throughout this guide NOTE CAUTION and WARNING vwill be used A NOTE indicates a condition that should be observed A CAUTION indicates a condition that may result in damage to the vehicle A WARNING indicates a hazard ous condition which could result in severe injury or death Please observe these notes cautions and warnings be aware that servicing a vehicle requires mechanical skill and a regard for conditions that could be haz ardou
14. not exceed 500 Ibs 227 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings kg and no more than 50 Ibs 23 kg tongue weight may be attached to the hitch Remember that the overall capacity of the vehicle operator passenger contents of load bed and accessories must be reduced to compensate for the trailer and load The range of motion of the trailer is limited by the ball and hitch The trailer should not be used on rough trails or over objects such as logs large rocks holes etc Never install baskets or extensions using the hitch receivers front or rear Such items will change the performance characteristics of vehicle and result in unsafe handling possible roll over or vehicle damage VEHICLE CLEANING AND CARE VEHICLE CLEANING To reduce the possibility of severe injury or vehicle damage read and understand all instructions supplied by manufacturer of pressure washer When pressure washing exterior vehicle do not use pressure in excess of 700 psi To reduce the possibility of cosmetic damage do not use any abrasive or reactive solvents to clean plastic parts It is important that proper techniques and cleaning materials be used Using excessive water pressure may cause severe injury to operator or bystander damage to seals plastics seat material body finish or elec trical system Do not u
15. of the charger LABELS AND PICTOGRAMS Vehicles may be labeled with pictograms as a method of conveying information or warnings Appendix A illustrates and explains picto grams that may appear on the vehicle Not all pictograms shown in Appendix A will be found on your vehicle SUN TOP AND WINDSHIELD The sun top does not provide pro tection from roll over or falling objects The windshield does not provide protection from tree limbs or flying objects The sun top and windshield provide some protection from the ele ments however they will not keep the operator and passenger dry in a 3 16 downpour This vehicle is not equipped with seat belts and the sun top has not been designed to provide roll over protection In addition the sun top does not protect against falling objects nor does the windshield protect against flying objects and tree limbs Keep arms and legs inside of vehicle while it is moving 12 VOLT POWER OUTLET Overuse of accessories may drain the battery and leave insufficient reserve to start the vehicle A 12 volt power outlet rated at 15 amps is located to the left side of the key light switch Ref Fig 15 on page 3 16 It provides constant power for accessories equipped with a 12 volt plug Q Outlet Fig 15 12 Volt Power Outlet TOWING A TRAILER The vehicle is equipped with a receiver that can be fitted with a stan dard 1 7 8 ball The trailer and its load must
16. optional winch Read under stand and follow all of the following information on the operation and use of the winch before attempting to operate it OPERATION OF THE WINCH The winch can be mounted at the front or rear of the vehicle and moved to accommodate different situations At the front it is mounted under the center of the front cowl to a bracket attached to the front axle as shown Ref Fig 2 on page 3 4 At the rear the winch is mounted upside down in the hitch receiver If mounting winch at rear of vehicle the winch must NOTE be mounted upside down Winch shown mounted at front of vehicle Front Axle Fig 2 Winch Mounted to Vehicle OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Before moving the winch unplug the winch connector from the wire harness To move the winch from one end of the vehicle to the other remove the spring pin pull out the clevis pin and remove the winch mount tube from the receiver Move to opposite end of vehicle and install by inserting clevis pin and securing with spring pin Plug the winch connector into wire harness The winch remote control plugs into the receptacle on the driver side of the seat support Ref Fig 3 on page 3 5 Remote Control Receptacle Fig 3 Winch Remote Control To unwind the cable locate the clutch knob on the winch Pull o
17. or in an area where gasoline is being han dled Do not perform procedures involving fuel system near open fire or electrical items which could produce a spark Do not handle gasoline in an area that is not adequately ven tilated Always wear safety glasses to prevent possible eye injury from gasoline or gasoline vapor To replace fuel filter use a pair of pliers to move clamps off ends of filter and pull filter up higher than the fuel pump to reduce the amount of gas that will spill Ref Fig 24 on page 3 30 Remove hose coming from fuel tank first and plug Remove filter from hose going to fuel pump and discard Orient direction of new fuel filter according to the NOTE FLOW arrow on the side of filter Install new fuel filter and reposition the clamps over the inlet and outlet CHECKING THE OIL LEVEL Tool List Qty Required GIO AM 2 Never overfill the engine with oil foaming may result and oil may enter the breather system When adding oil between oil changes do not mix brands and viscosity grades of oil Both the oil dip stick and fill cap must be in place before operating the engine Failure to install the dipstick and fill cap will result in oil becoming contaminated and or oil being discharged into the engine com partment Check oil level daily before starting the engine The vehicle must be on a level surface with the parking brake engaged Use a cloth to wipe clean the oil dipstick handle and oil fil
18. result in injury or death to the operator or passenger Do not modify the vehicle in any manner that will change the weight distribution of the vehicle Changes to the weight distribution or the cen ter of gravity may make it unstable or prone to roll over which could result in injury or death to the operator or passenger COMMON SENSE OPERATION This vehicle is not a toy If not operated properly and responsibly it can cause severe injury or death to the operator passenger or bystanders All operators should possess a valid driver s license Chil dren should not be permitted to operate the vehicle Children may not have the skill judgement or strength to operate this or similar vehicles Alcohol drugs and many over the counter medications reduce the abil ity of the driver to operate the vehicle safely Always review side effects of any medication with a doctor or pharmacist before operating vehicle Protective clothing and an approved motorcycle helmet are recom mended for operator and passenger at all times When driving at full speed on a dirt road loose surfaces or wet grass vehicle stopping distance will increase If the vehicle is fully loaded it will take longer to stop than with no load When operating vehicle in wet weather conditions remember that the brakes may need to be lightly applied in order to provide enough friction to dry the brake unit If wet the brakes will lose much of their effect Slow down when in unfami
19. result in the vehicle fall ing backwards Before operating load bed check to ensure no one is behind the vehi cle Never fill a gas can in the bed of a vehicle Static discharge could ignite gasoline vapor and cause an explo sion Always place a gas can on the ground before filling Never fill a gas can in the bed of the vehicle Static electricity is built up during the fueling process and could discharge causing the gasoline vapor to ignite ELECTRIC LIFT BED OPERATION Exercise caution while operating the electric lift bed to ensure clothing is not caught during lifting or lowering procedure Severe injury could result if bed is lowered and traps fingers or other body parts The electric lift switch is located on the driver side of the front seat panel Move the switch lever up to raise the load bed and down to lower Ref Fig 12 on page 3 12 3 11 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Fig 12 Electric Lift Switch OPERATING THE VEHICLE Improper use of the vehicle or the lack of proper maintenance may result in damage or decreased performance Read and understand the following warnings before attempting to operate the vehicle To reduce the possibility of severe injury or death resulting from loss of vehicle control the following warn ings must be observed When driv
20. speed in wet areas Use extreme caution and reduced speed when approaching sharp or blind turns Use extreme caution and reduced speed when driving over loose terrain Use extreme caution and reduced speed in areas where pedestrians are present 2 1 SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings MAINTENANCE The following information is very important in the maintenance of the vehicle The person performing maintenance procedures should read understand and always observe the following 2 2 Maintain your vehicle in accordance with the manufacturer s periodic ser vice schedule Ensure that mechanics performing repairs are trained and qualified to do SO Follow the manufacturer s directions if you perform maintenance on your own vehicle Be sure to disable the vehicle before performing any mainte nance Disabling includes removing the key from the key switch and removal of a battery wire Insulate any tools used within the battery area in order to prevent sparks or battery explosion caused by shorting the battery terminals or associated wiring Remove the battery or cover exposed terminals with an insulating material Check the polarity of each battery terminal and be sure to rewire the bat tery correctly Use specified replacement parts Never use replacement parts of lesser quality Use only tools recommended
21. to the touch stop winching and allow the motor to cool Always wear thick leather gloves when handling the wire cable 3 6 Replace frayed wire cable with a direct factory replace ment only Never operate the winch with less than five 5 full turns of cable around the drum Ref Fig 5 on page 3 6 Fig 5 Never Operate Winch with Less Than Five Turns Around Drum If the winch motor stalls from overloading do not continue to activate the winch remote control The wire cable may become overstressed Do not attempt to pull loads exceeding 1500 Ibs 680 kg To pull out the cable the free spool clutch knob must be used Pull out and rotate the knob If the cable is under any load the clutch may not release easily Jog out some of the cable to release the tension and operate clutch Pull out the desired amount of cable and secure Engage the drum by rotating the knob until it snaps in place Never operate the winch unless the clutch is engaged Have all persons and pets leave the area while operating winch Never allow anyone to remain in the vehicle OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings To prevent damage to the wire cable never hook the cable to itself Always use a nylon sling Ref Fig 6 on page 3 7 Ref Fig 7 on page 3 7 Ref Wca 2 Fig 6 Do Not Hook Cable to Itself Stay clear o
22. 26 When cleaning the outside of the battery and terminals first spray with a solution of sodium bicarbonate baking soda and water to neutralize any acid deposits before rinsing with clear water Use of a water hose without first neutralizing any acid will move acid from the top of the battery to another area of the vehicle or storage facil ity where it will attack the metal structure or the concrete asphalt floor Additionally a residue will be left on the battery which is conductive and will contribute to the discharge of the battery To reduce the possibility of battery explosion that could result in severe injury or death do not use metallic spray wand to clean battery and keep all smoking materials open flame or sparks away from the battery The correct cleaning technique is to spray the top and sides of the bat tery with a solution of sodium bicarbonate baking soda and water This solution is best applied with a plastic spray bottle The solution should consist of 2 teaspoons 10 ml of sodium bicarbonate baking soda mixed with 1 quart 1 liters of clear water Ref Fig 35 on page 3 36 In addition to the battery special attention should be paid to metal 3 36 components adjacent to the battery which should also be sprayed with the sodium bicarbonate baking soda solution C gt 1 quart 1 liter Clear Water 2 Teaspoons 10 ml Sodium Bicarbonate e Baking Soda Plastic Spray Bottle
23. 37 BRAKES e T 3 37 Dally c 3 37 PROLONGED STORAGE date tpa ementi aeta dex Pe pops 3 38 HARDWARE peas 3 38 Fig 37 Torque Specifications and Bolt Grades 3 39 CAPACITIES AND REPLACEMENT PARTS 3 40 Fig 38 Capacities and Replacement Parts 3 40 GENERAL SPECIFICATIONS 4 1 ST 48O 4 1 Fig 1 Vehicle Dimensions uncos eee tc re Free t geste etapas 4 2 Fig 2 Vehicle Incline Specifications 4 3 Fig Vehicle Turning Clearance 4 4 LIMITED WARRANT Y cio sean eoa a 5 1 DECLARATION OF CONFORMITY 6 1 LABELS AND PICTOGRAMG APPENDIX A SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings The Owner s Manual and Service Guide has been designed to assist in main taining the vehicle in accordance with procedures developed by the manufac turer Adherence to these procedures and trouble shooting tips will ensure the best possible service from the product To reduce the chance of personal injury and or property damage the following instr
24. 798 4311 FAX 010 1 706 771 4609 E Z GO DIVISION OF TEXTRON INC P D BOX 388 AUGUSTA GEORGIA 30903 0388 USA 5 To obtain a copy the limited warranty applicable to the vehicle call or write a local Distributor authorized Branch or the Warranty Department with vehicle serial number and manufacture date code The use of non Original Equipment Manufacturer OEM approved parts may void the warranty Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty When servicing engines all adjustments and replacement components must be per original vehicle specifications in order to maintain the United States of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED STORAGE All batteries will self discharge over time The rate of self discharge varies depending on the ambient temperature and the age and condition of the battery A fully charged battery will not freeze in winter temperatures unless the temperature falls below 75 F 60 C 5 TITLE PAGE TITLE PAGE MANUAL Inside Front Cover SERVICE BRAKE PEDAL tuto antea dtes 3 10 mii alidizinfii d zc 3 10 e oe ene E ENE E Uf i A LIN 3 10 DIEEERENTIALE EGG IS 3
25. 9 43 44 45 75808G01 s w Zt Wi Jj 5 S 2 Zn 3 s 74093 G01 See Following Pages 74093G01 For Explanation Of These Pictograms 1 23 27 18 20 22 17 15 See Following Pages For Explanation Of These Pictograms 1 35 75696G01 75696G01 Fig 1 Label Locations LABELS AND PICTOGRAMS P 35962 G01 35962G01 See Following Pages For Explanation Of These Pictograms 1 2 46 47 48 75851001 DO TAMPER WITH OR CHANGE THIS ADJUSTMENT OF THE GOVERNOR FAILURE TO COMPLY COULD RESULT IN SERIOUS PERSONAL INJURY AND WILL VOID THE VEHICLE WARRANTY 24880G01 Appendix A 1 LABELS AND PICTOGRAMS A WARNING See Following Pages For a Windshields do not Explanation Of Pictogram 30 other flying objects See Following Pages For Explanation Of Pictogram 49 WARNING Keep entire body inside car 27 1 ae See Following Y o Pages For See Following Pages P qf V Explanation For Explanation Of bow X Of These These Pictograms LA Pictograms 1 2 lt ES 1 2 12 10 8 71489 G01 d e 5 V Y 7 5 1 1 i 71489G01 See Following Pages For Explanation Of This Pictogram 35493G01 Fig 2 Label Locations Continued Appendix A 2 WARNING READ MANUAL WARNING USE CAUTION IN INCLEMENT WEATHER WARNING DO NOT OPERATE IF USING ALCOHOL OR DRUGS Fi
26. EYE DISPOSE OF PROTECTION BATTERIES IN LANDFILL DO NOT DRIVE ON NO SMOKING HIGHWAY WINDSHIELDS DO NOT PROVIDE PROTECTION HOT SURFACE FROM FLYING OBJECTS BATTERIES ARE HEAVY USE CARE LIFTING OPERATE FROM DRIVERS SIDE USE INSULATED ONLY TOOLS Fig 6 Pictogram Definitions Continued Appendix A 6 AND LEGS WITHIN VEHICLE TO OPERATE VEHICLE IN FORWARD TURN KEY TO ON MOVE DIRECTION SELECTOR TO FORWARD DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY TO OPERATE VEHICLE IN REVERSE TURN KEY TO ON MOVE DIRECTION SELECTOR TO REVERSE AN AUDIBLE DEVICE WILL SOUND DEPRESS ACCELERATOR PEDAL AND ACCELERATE SMOOTHLY Fig 7 Pictogram Definitions Continued LABELS AND PICTOGRAMS TO LEAVE A GASOLINE POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO FORWARD TO LEAVE AN ELECTRIC POWERED VEHICLE IN PARK APPLY PARKING BRAKE TURN KEY TO OFF MOVE DIRECTION SELECTOR TO NEUTRAL KEEP CLEAR HAND OR FINGERS CAN BE TRAPPED Appendix A 7 LABELS AND PICTOGRAMS Appendix A 8 ON POSITION OFF POSITION HEADLIGHTS UNLOCKED LOCKED Fig 8 Pictogram Definitions Continued DIFFERENTIAL LOCKED WARNING KEEP ENTIRE BODY INSIDE CAR Starting Model Year 2004 A Textron Company ExZ GO Division ef Textron Inc POBox 388 Augusta
27. Georgia 30903 0388 USA inside 1 800 241 5855 FAX 1 800 448 8124 Outside USA Phignex0910 14706 4 98 4311 010 1 706 771 4609 Gopynghted Matetial This man aflmay netbe reproduced in P A FLOS 7 in p rtwithho t hesexporess penmission of TEIM GON Vio ADEL URN ATA a VA 27259 EZ GO Division T exdrbn Inc SNS eS te hnical Gommunicatians Department
28. N AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Place the jack at the center of the front axle Raise the vehicle and posi tion jack stands under the frame crossmember as indicated Lower jack and test the stability of vehicle on the four jack stands If only front or rear of vehicle is to be raised place the chocks in front and behind each wheel not being raised in order to stabilize the vehicle Lower the vehicle by reversing the lifting sequence WHEELS AND TIRES Standard tires for this vehicle are uni directional NOTE and should never be moved from one side of vehi cle to the other This vehicle comes standard with uni directional tires Left side tires should always remain on the left side of the vehicle Right side tires should always remain on the right side of the vehicle Uni directional tires have an arrow on the sidewall indicating direction of rotation when moving forward Tire condition should be inspected per the Periodic Service Schedule Ref Fig 22 on page 3 26 Inflation pressures should be checked when the tires are cool Be sure to install valve dust cap after checking or inflating Tire Repair Tool List Qty Required Lug wrench DURO U 1 m ket 3 4 1 2 dri 1 NZ mpact socket Impact wrench 1 2 1 Fig 16 Lift
29. NG TRAILER 3 16 Fig 4 Winch Clutch Knob oet CHEER 3 5 WINCH APPLICATIONS 3 5 VEHICLE CLEANING AND CARE 2 3 17 Fig 5 Never Operate Winch with Less Than VEHICLE CLEANING E TERRE E A 3 1 7 Five Turns Around Drum 3 6 VEHICLE GARE PRODUCTS initiis bun Rb 3 17 Fig 6 Do Not Hook Cable to Itself ee 3 7 REPAIR 3 18 Fig 7 Use Nylon Sling and Install a Damper when Winching 3 7 LIFTING THE VEHICLE 3 18 Fig 8 Do Not Pull at Angle arietes 3 8 Fig 16 Lifting Vehicle tertie nean ens 3 19 CONTROLS AND INDICATORS 22002 clu 3 8 WHEELS AND sce Cum cer o te A c MEI 3 19 KEV EIGETSSUIITGEE 3 8 Tire Repair 3 19 Fig 9 Key Light Switch Low Oil Pressure Light and Fuel Gauge 3 8 Wheel Installation Nn 3 20 DIRECTION SELECTOR 3 9 Fig 17 Wheel Installation 2 0 0 000 41 440 3 21 Fig 10 Console Controls 3 9 LIGHT BULB REPLACEMENT Cr ee 3 21 ere iz 3 9 Fig 18 Headlight and Turn Signal Bulb Replacement 3 21 FUEL GADGE odas MSS 3 9 Fig 19 Tail and Brake
30. RVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings injury or death Charging must take place in an area that is adequately ventilated minimum of 5 air exchanges per hour To reduce the chance of battery explosion that could result in severe injury or death never smoke around or charge batter les in an area that has open flame or electrical equipment that could cause an electrical arc ENVIRONMENTAL CONCERNS As a responsible user practice respect for all wildlife and their habitat Respect private property and comply with all local laws and regulations governing the use of light duty utility vehicles Do not tamper with the exhaust system or governor The exhaust system has been tuned to the engine for maximum performance Removal or modification of the exhaust is annoying to other people and will not improve the perfor mance of the vehicle To prevent severe injury or death while driving be aware of the follow ing Environmental hazards such as steep slopes overhanging limbs etc Danger of fire when vehicle is operated over dry combusti ble organic material When driving be aware of environmental hazards such as steep slopes overhanging limbs etc Be aware of the danger of fire when the vehicle is operated over dry combustible organic material 3 4 OPTIONAL WINCH This vehicle may be equipped with an
31. S on page 4 1 If pressure is not designated in GENERAL SPECIFICATIONS inflate to pressure designated on tire sidewall All four tires should have the same pres sure for optimum handling characteristics Be sure to install the valve dust cap after checking or inflating The vehicle is fitted with low pressure tubeless tires mounted on one piece rims When removing wheels with an impact wrench use 3 20 only impact sockets Regular sockets are not designed for impact pressures exerted by power tools Generally the most cost effective way to repair a puncture in the tread is to use a commercial tire plug Tire plug tools and plugs are available at most auto NOTE motive parts outlets and have the advantage of not requiring the tire be removed from the wheel If the tire is flat raise vehicle and remove wheel Refer to Lifting the Vehicle for proper lifting procedure and safety information Inflate tire to maximum recommended pressure Immerse the tire in water to locate the leak and mark with chalk Insert tire plug in accordance with manu facturer s specifications To reduce the possibility of severe injury be sure mounting demount ing machine is anchored to floor Wear OSHA approved safety equipment when mounting demounting tires If the tire is to be removed or mounted the tire changing machine man ufacturer s recommendations must be followed in order to reduce pos sibility of severe injury Be sure to position tir
32. adequate to maintain the battery charge level The generator is not designed to charge a discharged battery When engine starts the clutches engage and cause vehicle to move making jump starting both dangerous and impractical If the vehicle battery has become discharged it must be charged using a 12 Volt charger that is rated at 10 amps or less Read and understand all instructions provided by the manufacturer of the charger 3 22 TRANSPORTING VEHICLE TOWING This vehicle is not designed to be It is recommended that the vehicle be moved by placing the entire vehi cle on a trailer flatbed truck or other suitable transport NEUTRAL LOCK To prevent the driven clutch from turning the rear wheels during service operations a neutral lock is located under the passenger side of the console panel Ref Fig 20 on page 3 23 To operate Turn the key switch to OFF and raise the passenger seat Place the direction selector in the forward position Reach under the passengers side of console panel and rotate the neutral lock lever clockwise until it snaps into the slot in the direction selector bracket as shown Next pull the direction selector handle to the rear until it locks in place in the neu tral position When in this position the direction selector remains locked in the neutral position To activate the direction selector pull the neutral lock lever out of the slot and rotate counter clockwise until it snaps into the detent p
33. ake On steep hills it is possible for the vehicle to coast at greater than nor mal speeds encountered on a flat surface To reduce the possible loss of vehicle control and severe drivetrain damage speeds should be lim ited to no more than the maximum governed speed on level ground see GENERAL SPECIFICATIONS Limit speed by applying service brake FUEL To reduce the possibility of severe injury or death from improper fuel handling Do not smoke near the fuel tank Do not refuel near open flame or electrical items which could produce a spark Always handle gasoline in a well ventilated area Always wear eye protection to protect against splashed fuel and fuel vapors Always allow adequate space for the expansion of gaso line Leave at least 1 2 5 cm space below bottom of filler neck Inspect fuel cap tank and other components for leaks or deterioration that could cause a hazardous condition The fuel tank is located under the seat on the passenger side of the vehicle Ref Fig 14 on page 3 15 Fill the tank with fresh clean auto motive grade gasoline Ref Fig 38 on page 3 40 High altitude or heavy use load applications may benefit from higher octane gasoline Do not use gasoline which contains Methanol FYXEPZZTe Some fuels called oxygenated or reformulated gasoline are gasoline blended with alcohols or ethers Excessive amounts of these blends can damage the fuel system or cause performance problems I
34. by the manufacturer Determine that tools and procedures not specifically recommended by the manufacturer will not compromise the safety of personnel nor jeopardize the safe operation of the vehicle Support the vehicle using wheel chocks and jack stands Never get under a vehicle that is supported by a jack Lift the vehicle in accordance with the manufacturer s instructions Never attempt to perform vehicle maintenance in an area where exposed flame is present or persons are smoking Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated until inspected and repaired e The manufacturer cannot anticipate all dangerous situations People attempting to maintain or repair the vehicle must have the skill and experi ence to recognize and protect themselves from potential dangerous situa tions These situations could result in severe personal injury or death and damage to the vehicle Use extreme caution and if unsure as to the poten tial for injury refer the repair or maintenance to a qualified mechanic Test drive the vehicle after any repairs are made or maintenance proce dures performed to assure the vehicle is safe to return to service All tests must be conducted in a safe area that is free of both vehicular and pedes trian traffic Replace damaged or missing warning caution or information labels Keep complete records of the maintenance history of the vehicle VENTILATION Alwa
35. cation To reduce the possibility of severe injury wear rubber gloves to protect skin from exposure to hot used oil and degreaser These fluids contain chemicals known to cause cancer The oil should be changed with the engine warm Park the vehicle on a level surface engage the parking brake and remove the key Place a 5W 30 10W 30 Synthetic 5W 20 5W 30 10 Air Temperature Fig 27 Oil Viscosity Chart drain pan under the engine Wipe the oil fill cap clean with a cloth and remove the cap Ref Fig 24 on page 3 30 Clean the area around the oil drain valve Ref Fig 28 on page 3 32 Open the valve and allow the oil to drain through the hole in the engine mounting plate Close valve once oil has drained Add 1 quart 1 liter of oil Start and drive vehicle at a slow speed for 30 seconds Stop and turn off vehicle on a level surface and wait 30 sec onds for the oil to settle to the bottom of the engine Check for leaks Slowly add more oil to bring level to the FULL mark on dipstick Do not overfill Replace dipstick fully into the dipstick tube and firmly replace the oil fil 3 31 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings LUBRICATION Oil Filter Do not use more than three 3 pumps of grease in each grease fitting at any one time E
36. concentration of hydrogen gas is explosive and could cause severe injury or death Charging must take place in an area that is adequately venti 3 1 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings lated minimum of 5 air exchanges per hour To reduce the chance of battery explosion that could result in severe injury or death never smoke around or charge batter les in an area that has open flame or electrical equipment that could cause an electrical arc Before a new vehicle is put into operation the items shown in the INI TIAL SERVICE CHART must be performed Ref Fig 1 on page 3 2 md Check air pressure see SPECIFICATIONS Fill tank with correct fuel Check oil level Initial change after 5 8 hours Record key number and store in safe location Fig 1 Initial Service Chart Vehicle battery must be fully charged before initial use Check for correct tire inflation See GENERAL SPECIFICATIONS Check for oil or fuel leaks that could have developed in shipment from the factory Check for a firm brake pedal Determine and record braking distance required to stop vehicle for future brake performance tests 3 2 Record and keep key number Remove the protective clear plastic that protect the seat bottom and back rest during shipping before placing the vehicle in service TERRAIN The vehic
37. discharged into the engine compartment 3 13 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings The oil should be changed in accordance with the Periodic Service Schedule while the engine is warm See SERVICE AND MAINTE NANCE for checking oil level and changing oil procedures COLD STARTING Starting a cold engine may require use of the choke Depress the accelerator approximately 1 2 5 cm or until the starter just begins to operate Pull the choke out if required Accelerate slowly and push the choke in completely when the engine runs smoothly Do not allow the starter to operate continuously for more than 10 seconds Allow 30 seconds between starting attempts If the vehicle does not start on the third attempt turn the key switch off set the park brake and determine the cause of the problem If the vehicle had been running and the engine does not start within 10 seconds use the choke STARTING AND DRIVING To reduce the possibility of roll back which could result in severe injury or vehicle damage do not release the service brake until engine has started To operate vehicle Apply the service brake place the key in the key switch and turn it to the ON position Move the direction selector to the direction desired Release the park brake by pressing the release button in the end of the handle w
38. dure and safety infor mation 3 25 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings PERIODIC SERVICE SCHEDULE Check Clean Agjust etc A Replace To perform service that is listed in this schedule but not described in this manual contact a local Service Representative or see the Repair and Service Manual for this vehicle NOTE Some maintenance items must be serviced more frequently on vehicles used under severe driving conditions BEFORE USE Check oil level Refer to page 3 29 see Note 1 on Pg 3 40 Check service brake general operation Check park brake function Check warning device function in reverse Check tire condition Check overall vehicle condition Clean fins and inside blower housing Refer to page 3 36 see Note 3 on Pg 3 40 WEEKLY 25 HOURS includes items listed previous table amp the following V Check level add if required DOT 3 and check for leakage Refer to page 3 37 Clean foam pre cleaner Refer to page 3 33 see Note 3 on Pg 3 40 Y Check for unusual noise vibration acceleration oil leaks Fig 22 Periodic Service Schedule 3 26 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings STEERING ASSEMBLY Check for abnormal play tightness of all hardware
39. e on wheel correctly Arrow on tire indicates rotation when moving forward Wheel Installation To reduce the possibility of component damage do not tighten lug nuts to more than 85 ft Ibs 115 Nm torque It is important to follow the cross sequence pattern NOTE HM when installing lug nuts This will assure even seat ing of the wheel against the hub OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings With the valve stem to the outside mount the wheel onto the hub with lug nuts Be sure to position the wheel on hub correctly with arrow indi cating direction of rotation when moving forward Finger tighten lug nuts in a cross sequence pattern Ref Fig 17 on page 3 21 Tighten lug nuts to 50 85 ft Ibs 70 115 Nm torque 20 ft lbs 30 Nm incre ments following the cross sequence pattern Cross Sequence Front of Vehicle Fig 17 Wheel Installation LIGHT BULB REPLACEMENT For vehicles with headlights mounted in cowl locate the two screws on backside of cowl that secure headlight Ref Fig 18 on page 3 21 Remove screws pull headlight out and disconnect wires Connect wires to new headlight install in cowl and secure with screws previ ously removed To replace the turn signal light bulb support turn signal housing from backside of cowl while removing two screws securin
40. e when tightening fasteners and refer to the Technician s Repair and Service Manual for specific torque values OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Generally three grades of hardware are used in the vehicle Grade 5 and grade 8 hardware is identified by 6 marks on the head Unmarked hardware can be identified by the three marks on the hexagonal head hardware is Grade 2 Ref Fig 37 on page 3 39 ALL TORQUE FIGURES ARE IN FT LBS Nm Unless otherwise noted in text tighten all hardware in accordance with this chart This chart specifies lubricated torque figures Fasteners that are plated or lubricated when installed are considered wet and require approximately 8096 of the torque required for dry fasteners BOLT SIZE 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 8 15 24 35 55 75 130 125 190 11 20 33 47 75 102 176 169 258 13 23 35 55 80 110 200 320 480 18 31 47 75 108 149 271 434 651 18 35 55 80 110 170 280 460 680 24 47 75 108 149 230 380 624 922 BOLT SIZE M6 M8 M10 M12 M14 Class 5 8 C 10 20 35 55 Grade 2 5 8 14 27 47 76 4 Class 8 8 18 35 61 97 Grade 5 58 8 47 83 131 Class 10 9 5 25 49 86 136 Grade 8 W3 66 117 184 Fig 37 Torque Specifications and Bolt Grades 3 39 OPERATION AND SERVICE INFORMATION
41. elf and those around you should the component move unexpectedly Some components are heavy spring loaded highly corrosive explo Sive may produce amperage or reach high temperatures Gasoline carbon monoxide battery acid and hydrogen gas could result in seri ous bodily injury to the technician mechanic and bystanders if not treated with utmost caution Be careful not to place hands face feet or body in a location that could expose them to injury should an unfore seen dangerous situation occur To prevent personal injury or death observe the following Before working on the vehicle remove all jewelry rings watches necklaces etc Be sure that no loose clothing or hair can contact moving parts Use care not to touch hot objects Raise entire vehicle and support on jack stands before attempting to run or adjust powertrain Hydrogen gas is formed when charging batteries Do not charge batteries without adequate ventilation Do not permit open flame or anyone to smoke in an area that is being used for charging batteries A concentration OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings of 4 hydrogen gas or more is explosive Engine exhaust gas carbon monoxide is deadly Carbon monoxide is an odorless colorless gas that is formed as a natural part of incomplete combustion of hydrocarbon fuels Carbon
42. es Dry all connections with forced air Reinstall the wires 3 17 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings VEHICLE CARE PRODUCTS To help maintain the vehicle there are several products available through local Distributors authorized Branches or the Service Parts Department Touch up paint specially formulated to match vehicle colors for use on both metal and molded plastic bodies P N 28140 G and 28432 G for solid colors 75831 G for camouflage colors Battery Protectant formulated to form a long term flexible non tacky dry coating that will not crack peel or flake over a wide tem perature range P N 75500 G01 e White Lithium Grease designed to provide lubrication protection in areas where staining or discoloring is a problem or in areas of extreme temperature ranges P N 75502 G01 Penetrant Lubricant a 4 in 1 product that penetrates seized parts lubricates leaving a light lubricating film reduces corrosion by adhering to wet or dry surfaces and displaces moisture sealing against future moisture return P N 75503 G01 Multi purpose Cleaner and Degreaser that contains natural envi ronmentally safe solvents P N 75504 G01 Multi purpose Hand Cleaner is an industrial strength cleaner con taining no harsh solvents yet gently lifts grease off hands May be used with or without wate
43. ess the release button in the end of the handle while slightly raising the handle then lower the park brake handle HORN The hom is operated by pushing the horn button located on the upper floorboard to the left of the brake pedal Ref Fig 11 on page 3 10 DIFFERENTIAL LOCK The rear drive axle is equipped with a manually operated locking differ ential With the differential unlocked if one drive wheel looses traction all available power is transferred to that wheel until it regains traction With the differential locked power is distributed to both drive wheels at all times Always disengage the differential lock after traction is regained With the differential locked steering effort and tire wear is increased due to the outside tire dragging during turns The differential lock should only be used when NOTE additional traction is required Continued use of the OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings differential lock may cause excessive wear to the rear tires The vehicle must be completely stopped before engaging or disengaging the differential lock Failure to stop will damage the differential To engage the differential lock stop vehicle and push the lock lever for ward towards the red locked symbol Ref Fig 10 on page 3 9 To disengage the differential lock stop the vehicle and push
44. f any undesirable operating symptoms occur use gasoline with a lower percentage of alcohol or ether Do not overfill the fuel tank Allow adequate space for the expansion of gasoline Leave at least 1 2 5 cm space below bottom of filler neck Fig 14 Fueling BATTERY Excessive use of accessories may drain the battery and leave insufficient reserve to start the vehicle 3 15 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings The vehicle uses a combination starter generator to both start the engine and charge the battery The engine will not idle therefore the battery cannot be charged while the vehicle is stopped Do not operate accessory items such as accessory lights radios winch etc exces sively while the vehicle is stopped The generator is capable of supplying 35 amps therefore operation of all accessories could result in the discharge of the battery even though the engine is running and the generator operating Discharging the bat tery is known as deep cycling The battery is not a deep cycle model but is a starting battery Multiple deep cycling will result in the premature failure of the battery If the vehicle battery has become discharged it must be charged using a 12 Volt charger that is rated at 10 amps or less and in accordance with all instructions provided by the manufacturer
45. f the winch the cable and the cable hook Place a heavy cloth jacket or blanket over the cable to act as a damper should the cable break when operating the winch Ref Fig 7 on page 3 7 Remember that the winch operation will drain the battery and may leave insufficient power to start the vehicle When operating the winch keep the entire area in view Never release the free spool clutch while the cable is under load Never work around the winch drum or the winch cable while it is under tension Ref Wcd 2 Fig 7 Use a Nylon Sling and Install a Damper when Winching Unplug the winch switch before working on the winch drum in order to prevent inadvertent operation When operating winch take up slack slowly Stop winch before cable becomes tight and inspect all winching con nections Check winch attachment hook attachment nylon sling if required and load attachment Do not pull at an angle This will cause the wire cable to pile up on one end of the winch This may jam the winch causing damage to the cable and or the winch Pulling the vehicle at an angle can cause damage to the front suspen sion and may cause the vehicle to overturn When pulling vehicle pull straight only Ref Fig 8 on page 3 8 If the vehicle is being used as an anchor to winch a load it should have the parking brake set and chocks installed on 3 7 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this
46. g 3 Pictogram Definitions LABELS AND PICTOGRAMS 147 125 CROSS ANGLE AS SPECIFIED WARNING MAXIMUM CROSS HILL RAMP ANGLE AS SPECIFIED LOAD WITH HIGH CENTER OF GRAVITY COULD RESULT IN TIP OVER LOAD CENTER OF GRAVITY MAXIMUM HEIGHT Appendix A 3 LABELS AND PICTOGRAMS WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY DANGER OF EXPLOSION MAXIMUM 1 2 m DO NOT FILL GAS CAN RAMP HILL IN LOAD BED SECURE LOAD WARNING MAXIMUM AS FAR FORWARD AS POSSIBLE LOAD amp CENTER OF Ibs MAXIMUM LOAD d B BED CAPACITY MAX LOAD GRAVITY 13 XXX LBS Xm KEEP LOAD ASFAR KG FORWARD t AS POSSIBLE DO NOT RIDE IN LOAD BED KEEP HANDS amp FINGERS DO NOT RIDE IN AWAY FROM LOAD BED 14 DUMP BED DO NOT STAND BEHIND DUMP BED Fig 4 Pictogram Definitions Continued Appendix A 4 CLEAN UP GASOLINE SPILLS WITH WATER BEFORE STARTING ENGINE UNLEADED GASOLINE DO NOT SPILL FUEL ON A HOT ENGINE GROUND FUEL PUMP LOW OIL PRESSURE NEGATIVE GROUND BATTERY DO NOT CONNECT POSITIVE BATTERY TERMINAL TO GROUND Fig 5 Pictogram Definitions Continued LABELS AND PICTOGRAMS SHORTING BATTERY TERMINALS MAY CAUSE EXPLOSION NO TAMPERING KEEP HANDS OUT WARNING CORROSIVE WARNING EXPLOSIVE WARNING LETHAL VOLTAGE DO NOT EXPOSE TO FLAME Appendix A 5 LABELS AND PICTOGRAMS DO NOT WEAR
47. g lens Ref Fig 18 on page 3 21 Install new bulb and replace lens Turn Signal Lens EX Headlight Bulb Turn Signal AT Housing C y Fig 18 Headlight and Turn Signal Bulb Replacement To replace the tail and brake light bulb roll the rubber bezel from around the edge of the taillight and remove lens Ref Fig 19 on page 3 22 Install replacement bulb and replace lens FUSE REPLACEMENT To replace fuses locate the fuse block under the driver side seat Pull out old fuse and replace with a new automotive type fuse Headlight and taillight bulbs and fuses are available from a local Distributor an authorized Branch or the Service Parts Department VEHICLE WITH A DISCHARGED BATTERY To reduce the possibility of severe injury or death from inadvertent motion do not attempt to jump start a vehicle 3 21 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Roll Rubber Bezel Away Tail Brake From LM a Light Rear Fender Fig 19 Tail and Brake Light Bulb Replacement The vehicle is equipped with a starter generator and does not idle When starting the engine the starter generator functions as a starter and with the engine running it functions as a generator With the short running times associated with this kind of vehicle the generator is more than
48. hich the cable is attached with the following considerations Make sure the object cannot be pulled over or otherwise damaged 3 5 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings The object the winch is attached to could fall on the vehicle and it s occupants If attaching the winch to a dead tree a section could fall When pulling vehicle with winch pull straight only Do not permit the cable to contact the side of the drum Do not pull vehicle at angle If the vehicle is pulled at an angle it could turn over causing severe injury or death to anyone in the area The winch cable could also become overstressed and break causing severe injury or death to anyone struck by the cable If the vehicle becomes stuck or up on an obstruction the vehicle may be moved using the winch The winch may be installed in either the front or rear receiver and held in place with the locking pin provided To prevent severe injury or death 7 read and understand the following before attempting to use the winch The winch is not intended to be used in any hoisting oper ation The rolling load capacity of the winch decreases with the steepness of the slope The winch is designed for intermittent duty only The elec tric motor should not be allowed to become excessively hot If the motor becomes uncomfortably hot
49. hile slightly raising the handle Then lower the 3 14 parking brake handle e Slowly depress the accelerator pedal to start the engine Release service brake when engine starts When the accelerator pedal is released the ignition circuit is de energized and the engine stops To stop the vehicle more quickly depress the service brake pedal When the direction selector is in the reverse posi NOTE i a warning signal will sound to indicate that the vehicle is ready to run in reverse STARTING THE VEHICLE ON A HILL To reduce the possibility of roll back which could result in severe injury or vehicle damage do not release the service brake until engine has started Do not hold vehicle on hill by using the accelerator and engine This will cause premature and excessive wear to drive train components To reduce the possibility of permanent damage to the drive system it is important to prevent excessive roll back when starting the vehicle on a hill Place left foot on service brake and release the park brake Depress accelerator with right foot and release the service brake by lifting left foot COASTING To reduce the possibility of severe injury or death from coasting at OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings above recommended speeds limit speed with service br
50. ician immediately Any electrolyte spills should be neutralized with a solution of 1 4 cup 60 ml sodium bicarbonate baking soda dis solved in 1 1 2 gallons 6 liters of water and flushed with water Aerosol containers of battery terminal protectant must be used with extreme care Insulate metal container to reduce the possibility of can contacting battery terminals which could result in an explosion Always install a positive stop to prevent load bed from unexpectedly falling It is in the best interest of both vehicle owner and service technician to carefully follow the procedures recommended in this manual Preven tative maintenance applied at recommended intervals is the best guarantee for keeping the vehicle both dependable and economical This vehicle will give years of satisfactory service providing it receives regular maintenance Refer to the Periodic Service Schedule for appro priate service intervals Ref Fig 22 on page 3 26 Refer to Lubrication Points for appropriate lubrication locations Ref Fig 29 on page 3 32 3 24 In any product components will fail to perform properly as the result of normal use age wear or abuse A vehicle requiring repair indicates the vehicle is no longer functioning as designed and should be considered potentially hazardous Use extreme care when working on any vehicle When diagnosing remov ing or replacing any components that are not operating properly con sider the safety of yours
51. ing the Vehicl Torque wrench 1 2 1 i UN OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings A tire explosion can cause severe injury or death Never exceed infla tion pressure rating on tire sidewall To reduce the possibility of tire explosion pressurize tire with small amount of air applied intermittently to seat beads Due to the low volume of the small tires overinfla tion can occur in seconds Never exceed the tire manufac turer s recommendation when seating a bead Protect face and eyes from escaping air when removing valve core To reduce the possibility of severe injury caused by a bro ken socket when removing wheels use only sockets designed for impact wrench use Use caution when inflating tires Overinflation could cause the tire to separate from the wheel or cause the tire to explode either of which could cause severe injury Use caution when inflating tires Due to the low volume of the small tires overinflation can occur in seconds Overinflation could cause the tire to separate from the wheel or cause the tire to explode Tire inflation will depend on the type of tires fitted but under no condition should inflation pressure be higher than recommended on the tire side wall Standard and optional tires should be inflated to pressure desig nated in GENERAL SPECIFICATION
52. ing vehicle consider the terrain traffic condi tions and the environmental factors which effect the ter rain and the ability to control the vehicle Use extra care and reduced speed when driving on poor surfaces such as loose dirt wet grass gravel etc Stay in areas suitable for a light duty utility vehicle Avoid rough unimproved trails areas with large rocks stumps 3 12 or holes and avoid steep slopes Maintain a safe speed when driving down hill Use service brake to control speed when traveling down an incline A sudden stop or change of direction may result in loss of control Slow down before and during turns All turns should be made at reduced speed Never drive vehicle up down or across an incline that exceeds 14 25 grade When driving the vehicle on unfamiliar terrain drive the vehicle slowly especially when cresting a hill If the vehicle is unable to climb a hill do NOT attempt to turn it around Turning the vehicle sideways on a hill could result in the vehicle rolling over Slowly back down the hill using the service brake to control speed When operating the electric dump do not back up to a drop off such as a loading dock or ravine Misjudgment or an unstable surface could cause the vehicle to fall back ward into the drop off To reduce the possibility of severe injury or death resulting from improper vehicle operation the fol lowing warnings must be observed The vehicle is a
53. ion Rack amp Pinion Dual Handgrips Cushion Foam Vinyl Cover Bucket Seats Hip Restraint Hand Hold Operator amp 1 Passenger 800 Ibs 365 kg Including Operator Passenger Accessories amp Cargo 500 Ibs 230 kg Maximum Bed Load 16 5 mph 26 5 kph Max Powder Coated DuraShield Welded Tubular Steel Tubular Steel Front Bumper with Brush Guards Flexible Impact Resistant DuraShield Injection Molded TPO Thermoplastic Olefin with Base Coat Clear Coat Front Cowl DuraShield Powder Coated Steel Rear Body ST Series Hunter Green ST ADVANTAGE Series RealTree Advantage Camo Body and Load Bed GENERAL SPECIFICATIONS DASH Scuff Resistant Glass Fiber Reinforced Plastic Thermoplastic Olefin with 4 Drink Holders LOABBED cete res Rotomolded cross link polyethelene amp Electric Dump LOAD BED FEATURES Hinged Removable Tailgate Removable Bed Sides LIGHTING HORN Standard Dual Halogen Headlights Horn TIRES Standard 22 x9 10 Stryker I9 Uni directional TIRE PRESSURE 12 16 psi 85 110 kPa WEIGHT Without Fuel 1100 Ibs 480 kg OPERATING CONTROLS amp INSTRUMENTATION Removable Key Deadman Accelerator Control Direction Selector Audible Reverse Warning Analog Fuel Gauge Low Oil Pressure Indicator and 12 Volt Power Outlet Specifications subject to change without notice
54. l cap Ref Fig 24 on page 3 30 This is necessary to prevent debris from falling into the engine Remove the dipstick and wipe off the entire area indicated with a clean cloth Ref Fig 25 on page 3 30 Insert the dipstick fully into the dipstick tube and remove Examine the level of oil on the dipstick Oil should be at the FULL mark Ref Fig 26 on page 3 30 3 29 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings If oil is required remove oil fill cap and add oil slowly to bring level to the FULL mark Do not overfill Replace dipstick fully into dipstick tube and firmly replace the oil fill cap When adding oil between oil changes do not mix NOTE NOTE brands and viscosity grades of oil Both the oil dip Stick and fill cap must be in place before operating the engine Failure to install the dipstick and fill cap will result in oil becoming Dipstick contaminated and or oil being discharged into the engine com partment Maximum oil level DO NOT OVERFILL 920502020006 pu Fuel Line TER Fig 26 Check Oil Level on Dipstick iid CHANGING THE OIL Tool List Qty Required mili E 1 ERE EET 1 renro 2 For maximum performance and longevity the engine oil should be replaced after the first five 5 to eight 8 hours of
55. le is designed for use on improved roads but not on public highways The vehicle may also be used on established trails or open terrain that is free from stumps large rocks or holes The vehicle should not be used to cross water VEHICLE CAPACITY Due to the variety of ways the vehi cle may be used it is important that the operator consider any potential hazards before use to prevent serious injury or death The vehicle may be used to transport a maximum of two people within the operator passenger compartment and cargo in the load bed Never carry passengers in the load bed The total payload is 800 Ibs 363 kg The weight of the driver and passenger plus any options or accessories must be deducted from the total payload rating to determine the load bed capacity Remember that towing a trailer will reduce the payload of the vehicle itself Remember that volume of your load can be misleading Loading the vehicle to its rated capacity with dry sand fertilizer sod etc can be handled with complete safety The same load when wet will grossly overload the vehicle and increase the potential for roll over and dam age to the vehicle OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings MODIFICATIONS TO VEHICLE Changes to the weight distribution or the center of gravity may make it unstable or prone to roll over which could
56. liar terrain Slow down when cresting a hill in an area that you are unfamiliar with Some hills are too steep to climb If you attempt to climb a hill that is too steep or if you are unable to achieve adequate traction do not attempt to turn around on the hill Slowly back straight down the hill using the service brake to control speed POWER CONSUMPTION The vehicle uses a combination starter generator to both start the engine and charge the battery The engine will not idle therefore the battery cannot be charged while the vehicle is stopped Do not operate accessory items such as accessory lights radios winch etc exces sively while the vehicle is stopped Overuse of accessories may drain the battery and leave insufficient reserve to start the vehicle The generator is only capable of supplying 35 amps therefore opera tion of all accessories could result in the discharge of the battery even though the engine is running and the generator operating Discharging the battery is known as deep cycling The battery is not a deep cycle model but is a starting battery Multiple deep cycling of the battery will result in the premature failure of the battery Vehicle battery must be fully charged before initial use Hydrogen gas is generated as a nat ural part of the lead acid battery charging process A 4 concentra tion of hydrogen gas is explosive and could cause severe 3 3 OPERATION AND SE
57. lleys Ref Fig 32 on page 3 35 Fig 32 Check Belt Tension with Gauge Although not as accurate the belt may be depressed with a finger A maximum deflection of 3 8 1 cm is acceptable for a new belt Ref Fig 33 on page 3 35 Tighten an existing belt to 75 80 lbs 34 36 kg tension using the same technique and inspect for cracking or wear A maximum deflec tion of 1 2 13 mm is acceptable Adjusting the Belt Loosen front and back pivot bolts of starter generator Ref Fig 34 on page 3 35 3 8 1 cm Max Deflection for New Belt 1 2 1 3 cm Max Deflection for Existing Belt Fig 33 Check Belt Tension with Finger Loosen adjusting bolt Use pry bar to force starter generator towards front of vehicle until proper belt tension is achieved Hold starter gener ator in place and tighten adjusting bolt Tighten pivot bolts to 25 ft lbs 35 Nm torque Adjusting Bolt Fig 34 Adjust Belt Tension 3 35 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings BATTERY CLEANING To reduce the possibility of damage to vehicle or floor neutralize acid before rinsing battery To reduce the possibility of damage to electrical components while cleaning do not use a pressure washer Cleaning should take place per the Periodic Service Schedule Ref Fig 22 on page 3
58. low oil to enter the air filter enclosure Differential Unlocked 3 9 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings If oil level is below ADD mark on dipstick add oil to bring level to FULL mark Refer to page 3 29 Drive vehicle a short distance and check oil pressure If oil pressure light does not come on continue to use vehi cle ACCELERATOR PEDAL Unintentional movement of the accelerator pedal may cause the vehicle to move which could result in severe injury or death With the key switch ON depressing the accelerator pedal starts the engine and the vehicle begins to move in the direction selected When the pedal is released the engine will stop Ref Fig 11 on page 3 10 To stop the vehicle more quickly depress the service brake Fig 11 Accelerator Brake and Horn 3 10 SERVICE BRAKE PEDAL Depressing the foot operated service brake pedal activates the wheel brakes slowing or stopping the vehicle Ref Fig 11 on page 3 10 PARK BRAKE The hand operated park brake is located on the console between the front seats Ref Fig 10 on page 3 9 The brake is engaged when the handle is raised and disengaged when the handle is in the full down position When leaving the vehicle unattended engage the park brake by raising the handle until it locks in place To release the park brake depr
59. monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal The following are symptoms of carbon monoxide inhala tion e Dizziness Vomiting Intense headache Muscular twitching e Weakness and sleepiness Throbbing in temples If any of these symptoms are experienced get fresh air immediately Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area SERIAL NUMBER PLATE LOCATION The serial number and manufacturing date code are located on a plate on the passenger side of the dash housing of the vehicle Ref Fig 21 on page 3 25 Design changes take place on an ongoing basis In order to obtain cor rect components for the vehicle the manufacturing date code serial number and vehicle model must be provided when ordering service parts prolong vehicle life some Fig 21 Serial Number Plate Location maintenance items must be serviced more frequently on vehicles used under severe driving conditions such as extreme temperatures extreme dust debris conditions frequent use with maximum load To access powertrain for routine maintenance lift seats Additional access may be obtained by raising or removing the load bed For major repair refer to appropriate Technician s Repair and Service Manual Some service procedures may require the vehicle to be lifted Refer to LIFTING THE VEHICLE for proper lifting proce
60. must be done in a safe location with regard for the safety of all personnel 3 37 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings After the vehicle has been put into service it is recommended that the brakes be checked daily by performing the following test Depress the brake pedal The pedal should have some free travel and then become hard A brake pedal that has no free travel excessive free travel or a spongy feel is indicating that a brake inspection is required A brake pedal that falls after it is applied indicates a leak in the master or wheel cylinders Check for adequate brake fluid level Adjust brakes if required and inspect system for fluid leaks PROLONGED STORAGE To prevent serious injury or death resulting from a possible explosion Do not handle fuel in an area that is not adequately venti lated Do not smoke near the fuel tank or refuel near open flame or electrical items which could produce a spark Store vehicle in a clean dry area Do not store in same area as a stove furnace water heater or other appliance that uses a pilot light or has a device that can create a spark When refueling inspect the fuel cap for leaks or breaks that could result in fuel spillage Always wear safety glasses while refueling to prevent pos sible eye injury from gasoline or gasoline vapor Keep hands clothi
61. ng and jewelry away from moving parts Use care not to contact hot objects Raise the rear of the vehicle and support on jack stands before attempting to run the engine 3 38 Preparing the engine for a prolonged storage period 30 days or more calls for a few simple steps to prevent a build up of varnish and gum in the carburetor and corrosion in the engine Raise the rear of the vehicle and support on jack stands Refer to Lifting the Vehicle for proper lifting procedure and safety informa tion Disconnect the fuel hose at the fuel tank and plug hose With proper ventilation depress the accelerator pedal and allow engine to run until it stops due to lack of fuel Remove spark plugs Refer to page 3 37 and pour about 1 oz 30 ml of engine oil into each cylinder Replace spark plugs ground spark plug wires and use starter to turn engine over a few seconds to distribute oil Add a gasoline additive to the tank in accordance with the manu facturer s recommendations Reattach fuel line to tank and drive the vehicle for several minutes to circulate the additive through the carburetor While engine is still warm change oil Refer to page 3 30 Clean body chassis and engine of debris mud chaff or grass Refer to page 3 36 HARDWARE Periodically the vehicle should be inspected for loose fasteners Fas teners should be tightened in accordance with the Torque Specifica tions table Ref Fig 37 on page 3 39 Use car
62. operation After the initial oil change it should be changed per the Periodic Service Sched Fig 25 Clean Entire Dipstick ule Ref Fig 22 on page 3 26 3 30 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings The oil must be high quality detergent oil classified For Service SF SG SH SJ or higher Do not use special additives and do not mix oil with gasoline The selection of oil viscosity is dependent upon the climate in which the vehicle will be used Most vehicles require SAE 30 oil how ever vehicles used in cold climates will require a multi viscosity oil Ref Fig 27 on page 3 31 Synthetic oil meeting ILSAC GF 2 API certification mark and API ser vice symbol with SJ CF ENERGY CONSERVING or higher is an acceptable oil at all temperatures Use of synthetic oil does not alter required oil change intervals NOTE Do not use special additives in recommended oil Do not mix oil with gasoline Air cooled engines run hotter than automotive engines The use of non synthetic multi viscosity oils BW 30 10W 30 etc in temperatures above 40 F 4 C will result in higher than normal oil consumption When using a multi viscosity oil check oil level more frequently SAE 30 if used below 40 F 4 C will result in hard starting and possible engine bore damage due to inadequate lubri
63. osition in the direction selector bracket HAULING To reduce the possibility of severe injury or death while transporting vehicle Secure the vehicle and contents OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Direction Selector Console N Front of gt Vehicle EN im 5 gt Direction Selector Bracket at Unlocked Position Locked Position dr ___ rotate 90 to unlock Detent Pull out and Neutral rotate 90 Lock to lock Fig 20 Neutral Lock Never ride on vehicle being transported Always remove windshield before transporting Maximum speed with sun top installed is 50 mph 80 kph If the vehicle is to be transported at highway speeds the sun top must be removed When transporting vehicle below highway speeds check for tightness of hardware and cracks in sun top at mounting points Always remove windshield when transporting Always check that the vehicle and contents are adequately secured before transporting The rated capacity of the trailer or truck must exceed the weight of the vehi cle see GENERAL SPECIFICATIONS for vehicle weight and load Lock the park brake and secure the vehicle using ratchet tie downs SERVICE AND MAINTENANCE To reduce the possibility of severe injury or death from improper servic ing techniques Do not a
64. paper cartridge is a dry unit Do not use oil on NOTE NOTE the cartridge 3 33 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Unscrew the knob securing the cartridge to the air cleaner base and remove plate Remove cartridge and inspect Replace if too dirty to clean or at the first sign of filter paper deterioration Clean cartridge by gently tapping on a flat surface To reduce the possibility of engine damage from ingesting unfiltered air ensure plate is centered and correctly seated on top of cartridge before securing with knob Place cartridge in air cleaner base Install plate centered and fully seated on top of cartridge Secure with knob and install pre cleaner over cartridge Replace air cleaner cover making sure that the entire flange around the bottom of the cover fits over the top edge of the air cleaner base Secure with the spring clips REAR AXLE The rear axle is provided with a lubricant level check plug located on the driver side at the rear of the housing Ref Fig 31 on page 3 34 Unless leakage is evident an annual lubricant check is sufficient Checking the Lubricant Level Tool List Qty Required Wrench 13 1 E 1 Clean area around check and fill plugs Remove the check plug correct lubricant level
65. r P N 75505 G01 e Battery Cleaner that neutralizes battery acids and dissolves termi nal corrosion and can be rinsed with water P N 75506 G01 Biodegradable Cleaner that breaks down grease to be easily wiped or rinsed away P N 75507 G01 Multi purpose Value Pack sampler includes 4 ounce 118 ml 3 18 aerosol cans of Battery Protector Penetrant Lubricant White Lith ium Grease and Carburetor and Choke Cleaner P N 75508 G01 Plexus plastic cleaner and polish removes minor scratches from windshield P N 28433 G REPAIR LIFTING THE VEHICLE Tool List Qty Required EE 1 JACK 4 CROCK ter MP Tr Herr M Te 4 To prevent possible injury or death resulting from a vehicle falling from a jack be sure the vehicle is on a firm and level surface Never get under a vehicle while it is supported by a jack Use jack stands and test the stability of the vehicle on the stands Always place chocks in front and behind the wheels not being raised Use extreme care since the vehicle is extremely unstable during the lifting process Some servicing operations may require the rear wheels or the entire vehicle be raised Install chocks in front and behind each front wheel Ref Fig 16 on page 3 19 Center jack under rear bumper Raise vehicle and locate a jack stand under the outer end of each rear axle Lower jack and test the stability of the vehicle on the two jack stands OPERATIO
66. s Improper service or repair may damage the vehicle or render it unsafe Engine exhaust from this product contains chemicals known in cer tain quantities to cause cancer birth defects or other reproductive harm The exhaust emissions of this vehicles engine NOTE complies with regulations set forth by the Environ mental Protection Agency EPA of the United States of America USA at time of manufacture Significant fines could result from modifications or tampering with the engine fuel ignition or air intake systems Battery posts terminals and relat ed accessories contain lead and lead compounds Wash hands after handling NOTE This spark ignition system meets all requirements of the Canadian Interference Causing Equipment Regulations Ce systeme d allumage par tincelle de v hicule respecte toutes les exigences du R glement sur le mat riel brouilleur du Canada 5 MANUAL amp SERVICE GUIDE ST 480 E Z GO Division of Textron Inc reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice E Z GO Division of Textron Inc is not liable for errors in this manual or for incidental or consequential damage that result from the use of material in this manual CUSTOMER SERVICE DEPARTMENT IN USA PHONE 1 800 241 5855 FAX 1 800 448 8124 OUTSIDE USA PHONE 010 1 706
67. s amp Stratton Repair Manual P N 272144 for VANGUARD V Twin Overhead Valve Engines REAR AXLE Replace lubricant CYLINDER HEAD AND PISTONS Clean combustion chamber deposits refer to Briggs amp Stratton Repair Manual P N 272144 for VANGUARD V Twin Overhead Valve Engines Fig 22 Periodic Service Schedule Note 1 Change oil after first 8 hours then after every 50 hours Note 2 Change oil every 25 hours when operating under heavy load or in high temperatures Note 3 Clean more often under dusty conditions or when airborne debris is present Clean foam pre cleaner first and replace paper car tridge if dirty Replace either if showing signs of damage 3 28 TIRE INSPECTION Tire condition should be inspected per the Periodic Service Schedule Ref Fig 22 on page 3 26 Inflation pressures should be checked when the tires are cool Be sure to install the valve dust cap after check ing or inflating SEAT PROP The driver seat is equipped with a prop for use every time the seat is raised To use lift seat up against steering wheel to allow the prop to move over the center console flange Ref Fig 23 on page 3 29 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Fig 23 Seat Prop REPLACING THE FUEL FILTER To prevent a possible explosion do not smoke near the fuel tank
68. se pressure in excess of 700 psi to wash exterior of vehicle Clean windshield with lots of water and a clean cloth Minor scratches may be removed using a commercial plastic polish or Plexus plastic cleaner available from the service parts department Normal cleaning of vinyl seats and plastic or rubber trim requires the use of a mild soap solution applied with a sponge or soft brush and wipe with a damp cloth Removal of oil tar asphalt shoe polish etc will require the use of a commercially available vinyl rubber cleaner The painted surfaces of the vehicle provide attractive appearance and durable protection Frequent washing with lukewarm or cold water and mild detergent is required to preserve the painted surfaces Occasional cleaning and waxing with non abrasive products designed for clear coat automotive finishes will enhance the appearance and durability of the painted surfaces Corrosive materials used as fertilizers or for dust control can collect on the underbody of the vehicle These materials will cause corrosion of underbody parts unless flushed occasionally with plain water Thor oughly clean any areas where mud or other debris can collect Sedi ment packed in closed areas should be loosened to ease it s removal taking care not to chip or otherwise damage paint If the engine does not start or runs improperly after NOTE washing remove the spark plug wires by pulling the spark plug boots never the wir
69. st be serviced per the Periodic Service Schedule Ref Fig 22 on page 3 26 for optimum engine life and performance To prevent engine damage be careful not to let debris fall into the carburetor when servicing the air cleaner To prevent water entering air cleaner and causing starting or engine problems replace air cleaner cover making sure the entire flange around the bottom of the cover fits over the top edge of the air cleaner base Secure with the spring clips Access the filters by unsnapping the spring clip on each side of the air cleaner and removing the air cleaner cover Ref Fig 30 on page 3 33 If necessary vacuum or wipe out any loose dirt or trash from the air cleaner base Pre Cleaner Service The foam pre cleaner is to be used ary Do not put NOTE oil on the foam Carefully remove pre cleaner from cartridge and wash it in liquid deter gent and water Rinse Dry by squeezing pre cleaner in a clean cloth Do not put oil on the pre cleaner Install pre cleaner over cartridge Replace air cleaner cover making sure the entire flange around bottom of cover fits over the top edge of the air cleaner base Secure with the spring clips Air Cleaner Cover Cartridge Pre cleaner Air Cleaner Base Fig 30 Air Cleaner Cartridge Service Do not use petroleum solvents pressurized water or compressed air to clean cartridge Doing so will damage the cartridge and will damage the engine The
70. the United States of America USA and are not equipped for operation on public streets Some communities may permit these vehicles to be operated on their streets on a limited basis and in accordance with local ordinances Vehicle capacity is limited to a maximum of two persons Never modify the vehicle in any way that will alter the weight distribution of the vehicle decrease its stability or increase the speed beyond the factory specification Such modifications can cause serious personal injury or death Modifications that increase the speed and or weight of the vehicle will extend the stopping distance and may reduce the stability of the vehi cle Do not make any such modifications or changes The manufacturer prohibits and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle GENERAL OPERATION The following information is very important in the operation of the vehicle The operator should read understand and always observe the following Use the vehicle in a responsible manner and maintain the vehicle in safe operating condition Read understand and observe all warnings and operation instruction labels affixed to the vehicle Follow all safety rules established in the area where the vehicle is being operated Reduce speed to compensate for unsuitable terrain or conditions Apply service brake to control speed on steep grades e Reduce
71. the differ ential lock lever backward towards the green unlocked symbol After unlocking the differential may remain locked if driving is resumed in a straight line This is a normal occurrence caused by pressure remain ing against the gears and not allowing the locking mechanism to release To avoid this simply turn the vehicle as acceleration begins or accelerate in reverse LOAD BED To reduce the possibility of severe AWARNING A injury or death read understand and follow the Danger label affixed to the front of the load bed The electric lift bed is the standard bed for the ST480 A load bed warning label is affixed to the front of the bed See Appendix A For safe operation of the vehicle this label must be understood See the load bed warning label for maximum load The load must be posi tioned in the bed as far forward as possible distributed in such a way that its center of gravity must not be higher than height noted on label and secured Failure to follow these instructions may result in severe injury damage the vehicle and or cause the vehicle to tip over Use extra care when operating loaded vehicle Do not permit any one to ride in the bed Do not drive the vehicle with the load bed raised or with the tailgate unsupported When using the electric lift on the ST 480 be sure to avoid backing up to the edge of a drop off such as a loading dock or ravine A misjudg ment of distance or an unstable surface could
72. the vehicle in accordance with the Periodic Service Schedule Service Parts Manuals Technician s Repair and Service Manuals and engine Repair Manuals are available from a local Distributor an autho rized Branch or the Service Parts Department When ordering parts or requesting information for your vehicle provide vehicle model serial number and manufacture date code BEFORE INITIAL USE Record the four digit key number and store in a safe NOTE place Individual keys can only be replaced if the key number is known Without a key number the entire ignition switch will have to be replaced if keys are lost Read understand and follow the safety label on the instrument panel Ref Appendix A Be sure you understand how to operate the vehicle its equipment and how to use it safely Maintaining good performance depends to a large extent on the operator Improper use of this vehicle could result in severe injury or death The ST Series vehicle is a light duty utili ty vehicle It is NOT an all terrain vehicle This vehicle is not a toy and using it while engaging in horse play is dangerous Plan carefully before using the vehicle to go significant dis tances over questionable terrain Remember that a one hour drive may take many hours to walk out should you run out of fuel or be stranded by becoming stuck on unsuitable terrain Hydrogen gas is generated as a natural part of the lead acid battery charging process A 4
73. tive clothing are recom mended for operator and passenger at all times Do not permit anyone in the load bed while vehicle is in motion Use caution when operating the electric dump Do not allow anyone behind the vehicle when operating the unit When operating the winch observe all warnings and safe ty decals on the vehicle Read understand and follow the instructions located in the front part of this manual Do not winch at an angle Do not exceed winch capacity RUN IN Check for oil or fuel leaks that could have developed in shipment from the factory Avoid full throttle starts and rapid acceleration until the engine has achieved operating temperature All engines consume more oil than normal during the first hours of operation As internal moving parts are run in oil consumption should gradually decrease until the rate of consumption stabilizes Check the oil level per the Periodic Service Schedule Add oil if the level on the dipstick indicates that oil is in the add oil range Ref Fig 13 on page 3 13 Maximum oil level DO NOT OVERFILL lt lt ADD PULL AAS Fig 13 Check Oil Level on Dipstick Never overfill the engine with oil foaming may result and oil may enter the breather system Both the oil dipstick and fill cap must be in place NOTE before operating the engine Failure to install the dipstick and fill cap will result in oil becoming contaminated and or oil being
74. ttempt any type of servicing operations before reading and understanding all notes cautions and warn ings in this manual Any servicing requiring adjustments to be made to the powertrain while the engine is running must be made with both drive wheels raised and vehicle properly supported on jack stands To reduce the possibility of engine damage never operate vehicle at full throttle for more than 4 5 seconds while vehicle is in a load condition Wear eye protection when working on the vehi cle Use extra care when working around bat teries or using solvents or compressed air To reduce the possibility of causing an electrical arc which could result in a battery explosion turn off all elec trical loads from the battery before removing battery wires 3 23 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Wrap wrenches with vinyl tape to reduce the possibility of a dropped wrench shorting out a battery which could result in an explosion Reduce the possibility of accidental starting by removing and grounding spark plug wires and disconnecting battery at negative terminal before servicing The electrolyte in a battery is an acid solution which can cause severe burns to the skin and eyes Treat all electro lyte spills to the body and eyes with extended flushing With clear water Contact a phys
75. uctions must be carefully observed GENERAL Many vehicles are used for a variety of tasks beyond the original intended use of the vehicle therefore it is impossible to anticipate and warn against every possi ble combination of circumstances that may occur Good common sense and prudent driving practices do more to prevent acci dents and injury than all of the warnings and instructions combined The manu facturer strongly suggests that the owner operator read this entire Owner s Manual and Service Guide paying particular attention to the CAUTIONS and WARNINGS contained therein It is further recommended that other operators be encouraged to do the same If you have any questions contact your closest representative or write to the address on the back cover of this publication Attention Product Service Depart ment E Z GO Division of Textron Inc is not liable for errors in this manual or for incidental or consequential damages that result from the use of the mate rial in this manual E Z GO Division of Textron Inc reserves the right to make design changes without obligation to make these changes on units previously sold and the information contained in this manual is subject to change without notice This vehicle conforms to the current applicable standard for safety and performance requirements These vehicles are designed and manufactured for off road use They do not conform to Federal Motor Vehicle Safety Standards of
76. ut knob and rotate 90 to lock out Using handsaver bar pull cable from winch drum Leave at least five turns of cable on drum Re engage drum by turning clutch knob 90 returning it to original position Ref Fig 4 on page 3 5 To wind cable use handsaver bar to keep tension on the cable while activating remote When winding cable make sure the cable winds tightly and evenly onto the drum leaving no gaps that could cause pre mature wear to the cable When using winch under a load operate the remote control from as far to the side of the vehicle as possible Do not operate winch while sitting in passenger seat Read the following sec tion Winch Applications before attempting to operate winch ENGAGED q LOCKED OUT Clutch Knob Turn 90 Fig 4 Winch Clutch Knob WINCH APPLICATIONS The winch may be used for a number of purposes including pulling the vehicle if it loses traction on unsuitable terrain Improper use of the winch could result in a number of conditions that could cause severe injury or death to operator occupants of vehicle or bystander It is impossible to predict all conditions that the winch could be used therefore the following warnings should not be considered as complete Before operating the winch consider the possible dangers and take precautions to protect yourself your passenger and any bystanders To prevent severe injury or death to operator occupants or bystanders select the object to w
77. vehicle Pay particular attention to all Notes Cautions and Warnings CONTROLS AND INDICATORS Correct Vehicle controls and indicators consist of key light switch direction selector e choke fuel gauge low oil pressure light e accelerator pedal brake pedal e park brake Incorrect horn e differential lock KEY LIGHT SWITCH Located on the dash panel this switch enables the basic electrical sys Re tem of the vehicle to be turned on and off by turning the key To prevent inadvertent operation of the vehicle when left unattended the key Fig 8 Do Not Pull at Angle should be turned to the OFF position and removed Ref Fig 9 on page all wheels 3 9 Never use the winch to lift people or other overhead loads If the vehicle is equipped with lights the key switch has a position to Do not use the winch to secure loads Use a tie down operate them indicated by the light icon designed for the job If the vehicle is equipped with factory installed cus Do not apply shock loads to the Winch tom accessories some accessories remain opera tional with the key switch in the OFF position DIRECTION SELECTOR To reduce the possibility of Do not attempt to modify or weld the winch 3 8 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings zd mE Gauge Q 1 a Low Oil
78. xcess grease may cause Oil Drain grease seals to fail or grease migration into areas that Valve could damage components Putting more than three pumps of grease in a grease fitting could dam age grease seals and cause premature bearing failure Ref Fig 29 on page 3 32 King Pin Idler Arm Fig 28 Oil Drain Filter CHANGING THE OIL FILTER Tool List Qty Required Oil filter wrench to fit 3 76 mm oil filter 1 Feri gez eT 1 Clean Cl OUD me T 2 mE Ball Joint Steering Clean the area around the oil filler and oil drain Drain engine oil per on Rack Unit Changing the Oil and remove oil filter Ref Fig 28 on page 3 32 and Rod Make sure the seal came with filter and is not stuck to the engine Wipe around the sealing surface of filter mount with a clean lint free cloth Lightly oil the seal on the new filter with fresh clean oil Screw fil ter on by hand until the seal contacts the filter mount Tighten 1 2 to 3 4 turn more Refill engine with new per Changing the Fig 29 Lubrication Points 3 32 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings AIR CLEANER INSPECTION AND REPLACEMENT The air cleaner is a dual filter cleaner equipped with a foam pre cleaner over a conventional paper cartridge The filters mu
79. ys store gasoline vehicles in a well ventilated area to prevent gasoline fumes from accumulating Never fuel a vehicle in an area that is subject to flame or spark Pay partic ular attention to natural gas or propane water heaters and furnaces Never work around or operate a vehicle in an environment that does not ventilate exhaust gases from the area Carbon monoxide is a dangerous gas that can cause unconsciousness and is potentially lethal OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle Pay particular attention to all Notes Cautions and Warnings Thank you for purchasing a light duty utility vehicle Before driving the vehicle we ask you to spend some time reading this Owner s Manual and Service Guide and the Operating and Maintenance Instructions manual provided by the engine manufacturer These manuals contain the information that will assist you in the safe operation of the vehicle They will also assist you in maintaining this highly reliable vehicle Some illustrations may show items that are optional for your vehicle This vehicle has been designed and manufactured as a World Vehi cle Some countries have individual requirements to comply with their specifications therefore some sections may not apply in your country Most of the service procedures in this guide can be accomplished using common automotive hand tools Contact your service represen tative on servicing

E-Z-GO ST 480 Offroad Vehicle User Manual

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